2 x Lid Front Hinge 1135 8 x M8 Bolt 8 x M8 Washer (3mm Thick) 4 x M6 Large washers 4 x M6 Spring washers 4 x M6 x 40mm Bolts 6 x M6 20mm Bolts 6 x M6 Washers 20 x Screws 2 x Lid mount gas strut bracket 1041 2 x Self tap strut mount 1040 1 x Central Lock bracket 1510 2 x Front Tub Mount 1177 2 x Front Tub Mount Pins 2 x Gas struts (220N) 700mm long 1 x Plastic tube 500mm 1 x Wiring loom CW40 5 x Zip ties 1 x Alcohol wipe 1 x Instruction manual Fitting kit made by : Page 1 of 20
Fitting Instructions Part Number Holden RG Colorado Dual Cab 2012+ To suit Sports Bars Check contents of kit before commencing fitment and report any discrepancies *Image example shown only IMPORTANT Do not stand/sit or rest heavy objects on Tonneau Cover Humans or animals are not to be under the closed Tonneau at any given time Securely lock tonneau Cover before operating vehicle Tonneau Cover is not dust or water tight Do not carry open volatile chemicals with Tonneau Cover installed If contact with volatile chemicals occur, clean Tonneau with mild detergent and water solution Care Instructions Read Instructions fully before commencing installation. Clean Tonneau Cover with a mild detergent and water solution Do not use abrasive cleaners or solvents Refer to manufactures instructions applicable to power drill. Protect Tub floor against scratches during installation process. Maintenance If lubrication of the locks or hinges is required use only Graphite Powder. DO NOT use any other lubricants or oils. Tools Required Pen / Marker Die Grinder & multi tool Soapy water solution Centre Punch Masking Tape Allen Key set (Metric) Drill & Drill bits Scissors & Knife Phillips head screwdriver Ruler Caulking Gun Spanner & Socket Silicon - Non Acetic Tape measure Page 2 of 20
Installation Steps Flow Chart START SPORTS BAR REMOVAL TUB PREP FOR LID INSTALL LID INSTALL AND ADJUSTMENT WIRING FINISH Page 3 of 20
Remove the Sports Bars from the vehicle & retain the hardware for re-installation. NOTE: Two people are required. Thoroughly clean installation areas. Important: Instructions are for Utes with an UNDER-RAIL tubliner. If you have an OVER-RAIL tubliner you must trim the top off. Find the centre of the bed and mark the position. Page 4 of 20
Hinge mounts: Align the hinge mounts along front of tray, ensuring the hinges are properly positioned from centre of tub 460mm to centre of hinge mount either side along the inside of the front of tub. Attach the hinges using self-drilling screws (supplied) through holes pre-drilled into the hinges. Apply clear or black silicone to any gaps and between the hinges and the vehicle to prevent water entry. 460mm 460mm Measure and mark the positions as indicated above from the centre of the bed for placement of the bottom hinges. WARNING: RECHECK DIMENSIONS TO ENSURE CORRECT MEASURENT Drive the self-tapping screws through the holes in the top and the base of the hinge plate into the tub. Tighten to 3Nm. Gas Struts: Measure from the front rail inside of tub, measure along top edge of tray 780 mm (windscreen end) then down 20mm and mark the screws position for the gas strut bracket. Position the gas strut bracket accordingly, mark two mounting holes and centre. Refer to Fig. 1 and Fig. 2 780 mm 20 mm Fig.1 - Gas strut bracket location Fig.2 - Gas strut bracket location Page 5 of 20
Using a 2 mm diameter drill bit set to 5 mm drill stop. Drill two pilot holes. Attach small gas strut bracket using self drilling screws provided. Repeat process on other side of tray. Refer to Fig. 2 and Fig.3 Fig.3 - Gas strut bracket fitment Attach small shaft end of gas strut onto gas strut brackets, by clicking them in place. Refer to Fig.4 with regard to gas strut orientation. Fig.4 - Gas strut orientation With the lid on the floor and taking care to prevent damage or scratches to the painted surface, fit the upper gas strut mounting brackets to the lid using 20mm M6 Screws and Washers. Refer to Fig. 5 Fig. 5- Hard Cover strut bracket location Page 6 of 20
Important: DO NOT over tighten screws. Recommended tightening torque is 1-3 Nm Turn the Sportsbar upside down. Remove front brackets from sports bar only. Use 3 washer spacers inbetween bracket and sports bar, make sure bracket is pushed out to the outside face of the bars. Now tighten all bolts, this process is completed easier if done one leg of sports bar at a time. Front Silicon needs to be applied to the underside of the moulded feet cups to minimize the chance of water leakage. Rear Page 7 of 20
Place Sports Bar on protective mat (not supplied) to avoid scratching. Place corner pieces over ends of Sports Bar legs as shown. Loosely attach corner pieces to Sports Bar using the M6 phillips head screws, M6 flat washers and M6 spring washers as shown. Position Sports Bar and corner pieces on tub Loosely attach front legs of Sports Bar with one (1) M6 hex bolt, two (2) M6 flat washers and one (1) M6 nyloc nut (per side) as shown. IMPORTANT: Do not tighten Page 8 of 20
Attach lid hinges to tub hinges by aligning and pushing pin through. Click pin down into hinge locking tab Fit the lid and adjust so it is even on both sides and forward as far as possible while staying level. Note: When gas struts are fitted, lid will be pulled back slightly. When lid is aligned correctly, secure the catch hinge to the lid using 4 M8 Thick Washers and M8 Bolts Important: Ensure tongues are fully inserted into the hinge slots with hinge pin securely in place. Page 9 of 20
Check clearance of tonneau cover to vehicle rear corners. Ensure the tailgate is open and close tonneau cover. Check clearances at both rear corners between tonneau cover and sheet metal. Gaps should be consistent. If tonneau cover is touching sheet metal or gaps are not even, adjustment of the tonneau position may be required. With the Hard Tonneau Cover opened, attach the cylinder end of each gas strut onto the mounting brackets attached to the Hard Tonneau Cover by clicking into place Refer to Fig. 9 Fig. 9 - Attach gas strut Important: If you have purchased a Central Locking Ute Lid please ignore the next page concerning Lock Bracket Installation and Lock Bracket adjustment. Page 10 of 20
Important: This page for Manual Locking lids ONLY Please skip this page if you have purchased a Central Locking Lid Lock Brackets: To fit lock brackets, open tailgate and close the Hard Tonneau Cover. Make a mark where the lock cam (arm) lines up with the sides of the tub. Open Hard Tonneau cover and locate the two pairs of bolts on either side of the tub near the tailgate. Remove the rear bolt and place striker hinge - aligning the middle hole with the bolt hole and re-bolt. Ensure that there is allowance for up and down adjustment of the bracket. Repeat on other side. Refer to Fig. 11 Fig. 11 - Install lock bracket Close the Hard Tonneau Cover and try the locks. You may need to adjust the lock brackets on the Ute tub up or down. When correctly adjusted, you should need to apply slight pressure to the lid in order to operate the locks. Refer to Fig. 12. Fig. 12 - Lock bracket adjustment Important: Excess tension could damage the lock. Page 11 of 20
RG COLORADO DUAL CAB CENTRAL LOCKING WIRING INSTRUCTIONS Part no s: C40C, 210mm 190mm Measure 190 mm towards the centre from the top inside edge of tub and 210 mm down from top as shown above. At this point drill a 25 mm hole using a holesaw to go through the tubliner and the metal support behind as well only. Making sure the rear seat is folded down using a 10mm drill bit, drill in the centre of the hole made previously, drill right through the cab of the Ute and inner plastic trim. On the inner liner where you have drilled through with your 10mm drill bit, now drill a hole with a 25mm holesaw. Take off black cable release handle,10 mm nut and the 15 mm nut with washer. Leave the last washer and nut as is. The cable release will already be assembled as above. Page 12 of 20
With the nut and washer in position feed the cable through the body making sure it comes out in the interior of the Ute cab. As seen on the left now place a washer first through the cable followed by a gold 15mm nut, tighten the nut with a 15mm ratchet. Make sure the plastic trim is not obstructing the cable release. Finally tighten the 10mm gold nut on the end of the cable release followed by the black handle. Once the black handle is tightened all the way turn the 10mm gold nut tightened previously behind the handle anti-clockwise until it meets up with the inner tip of the black handle. Make sure the handle securely tightened. At this time it is best to engage the lock on the lid by pushing the lock lever up so it goes into lock position. Then pull on the cable release from inside the cab to ensure that the lock opens manually. Page 13 of 20
Locate the end of the supplied central locking harness fitted with a 3-way connector. From the battery, feed this end of the harness across the rear of the engine bay and down underneath the vehicle, leave for now. Make sure the harness is secured every 300mm and free from heat danger or moving parts. Connect the red wire to the positive battery terminal and the black wire to the negative battery terminal. Note: It is recommended to leave the black wire disconnected until after the harness fitment is complete. Page 14 of 20
Route the harness along the top of the right hand side chassis rail and secure with cable ties (1) every 300mm. Make sure the harness will not be affected by high temperatures and keep it away from any moving parts. Route the harness up at the front face of the tub and through the previously drilled hole. To achieve this, a guide wire (2) or something similar must be fed down through the hole in the tub. Fix the end of the central locking harness to the guide wire with tape or similar and pull the harness up through the hole with the guide wire. Remove the harness from the guide wire and seat the harness grommet into the hole in the tub metalwork. Connect the central locking harness (3) to the mating ute lid harness connector (4). Locate the floorpan grommet (5) underneath the right hand side of the floor pan, almost directly below the drivers feet. Pierce a hole in the grommet and feed the two wire part of the harness up through the grommet. Be sure to seal around the wire hole in the grommet with a suitable sealant and secure the harness where necessary. Page 15 of 20
6 7 Remove foam tape to access wires. Note: Use thinner brown & yellow wire Remove the driver s side front kick panel (6) and scuff plate (7). Locate the white connector which is one of three behind the kick panel and will be tucked into the body. From the rear side of this connector find the brown wire with a yellow trace and the grey wire. Note: There will be two brown with yellow trace wires. Connect the thinner wire of the two. Locate the green wire on the central locking harness and join to the brown with yellow trace wire using the supplied scotch clamp splices and spade connectors. The scotch clamp splices need to be lightly squeezed together with pliers. Repeat this to join the brown with black trace to the grey wire of the body harness. Coil up any excess wire of the central locking harness and locate in kick panel area. Re-Fit the drivers side kick panel and scuff plate. Connect black wire of central locking harness to the battery negative terminal (if not connected). Page 16 of 20
Align the center hole of the latch with the top of the center of the tailgate, making sure the bottom of the latch is facing down. With the self drilling screw provided gently screw through so it is still able to move up and down. With the lid open now close the tailgate. Climb into the tub with a torch light and Phillips head screw driver, with the aid of another person now bring the lid down slowly. Once the lid lock catches the latch and is aligned, tighten the self drilling screw all the way and ask the other person to open the lock by pressing the open button on the factory key. If the lock from the lid is not matching correctly it is wise to open the black cover of the central locking unit and loosen the lock unit by opening the 6 screws half way and adjusting the lock to meet the latch on the tailgate to get the best result. Retighten the screws and replace the black cover making sure all wires are not obstructed. Hard Lid light switch located on Lock Unit. Page 17 of 20
REMOVAL OF TONNEAU COVER FIGURE 1 1. Open tonneau cover. Disconnect harness at front Header bar. Detach gas strut (1) by inserting a small screwdriver and adjusting the spring clip (2) on the gas strut(1). Refer to figure 2. NOTE: Do not remove the spring clip, only a small amount of levering is required to detach. FIGURE 2 NOTE: 2 people are required to lift and remove the tonneau cover from the vehicle. 2. Remove hinge pins (1) and remove tonneau cover (2). Refer to figure 3. FIGURE 3 Page 18 of 20
REPLACEMENT OF TONNEAU COVER FIGURE 4 NOTE: 2 people are required to lift and fit the tonneau cover onto the vehicle. 1. Fit tonneau cover (2) and secure hinges with hinge pins (1). Refer to figure 5. FIGURE 5 2. Attach gas struts (2) by clipping into place. Ensure narrow end (1) mounts to the vehicle. Reconnect harness at front header bar. Refer to figure 6. FIGURE 6 Page 19 of 20
Paint care instructions: Your new painted Hard Tonneau Cover has been covered with a plastic film to protect the paint from damage. It will require cleaning and possibly light polishing after the protective film has been removed. Use polish as per new paint on a new vehicle. Wash Hard Tonneau Cover using water and normal carwash detergent and polish with an automotive polish. NOTE: Please ensure Lid is kept locked at all times when not being used, for both safety and longevity. Having trouble? Call your Supplier. Page 20 of 20